Steps 1-60
AssemblyPart 1:
Part 2:
Special Tool(s)
Material
Part 1:
Part 2:
Cylinder Head and Valve Train
Part 1:
Part 2:
Lower End
Part 1:
Part 2:
Lower End Exterior Dress
Part 1:
Part 2:
Upper End Exterior Dress
1. Install the Knock Sensors (KS) and 2 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
2. Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
3. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean and dry.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gaskets ability to seal correctly. Do not scratch the gasket.
CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 inch) across a 38.1 mm (1.5 inch) square area.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
Install new gaskets and position the cylinder heads on the engine.
4. NOTE: The cylinder head bolts are a torque to yield design and must not be reused. Always use new bolts.
Install and tighten the RH head bolts in 4 stages in the sequence shown.
^ Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 ft. lbs.).
^ Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 ft. lbs.) and an additional 90 degrees.
^ Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
5. Install the 2 bolts and tighten in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
6. Install and tighten the LH head bolts in 4 stages in the sequence shown.
^ Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 ft. lbs.).
^ Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 ft. lbs.) and an additional 90 degrees.
^ Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
7. Install the 2 bolts and tighten in 2 stages.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
8. NOTE: Coat the valve tappets with clean engine oil prior to installing.
Install the valve tappets and shims in their original location.
9. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
Position the RH camshafts on the camshaft journals.
10. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
Install the RH camshaft bearing caps.
^ Position the bearing caps.
^ Install the bearing cap bolts. Tighten the bolts in 3 stages in the sequence shown.
- Stage 1: Hand tighten.
- Stage 2: Tighten to 6 Nm (53 inch lbs.).
- Stage 3: Tighten an additional 90 degrees.
11. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
Position the LH camshafts on the camshaft journals.
12. CAUTION: Install the camshaft bearing caps. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
Install the LH camshaft bearing caps.
^ Position the bearing caps.
^ Install the bearing cap bolts. Tighten the bolts in 3 stages in the sequence shown.
- Stage 1: Hand tighten.
- Stage 2: Tighten to 6 Nm (53 inch lbs.).
- Stage 3: Tighten an additional 90 degrees.
13. CAUTION: If any components are installed new, the engine must be reshimmed or engine damage can occur.
Using a feeler gauge, confirm that the tappet and shim clearances are within specification.
14. If tappet and shim clearances are not within specification, adjust the clearance.
15. Install the engine lifting equipment and remove the engine from the stand.
16. CAUTION: The plastic sleeve that comes with the new crankshaft rear oil seal, protects the seal while in transit and is also used as an installation tool to prevent lip seal roll when carrying out the repair. The sleeve must be used to prevent future seal concerns.
NOTE: Lubricate the cylinder block bore and the crankshaft with clean engine oil before installing the seal.
Position the rear oil seal with protective installer onto the end of the crankshaft.
17. Using the special tool, install the rear main seal.
18. Install the flexplate and tighten the bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 15 Nm (11 ft. lbs.).
^ Stage 2: Tighten to 110 Nm (81 ft. lbs.).
19. Mount the engine on a suitable engine stand.
20. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
Install the special tool.
^ Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
^ Install the special tool.
21. NOTE: LH shown, RH similar.
Position all of the camshafts so the flats of the camshafts are facing upward.
22. Install the LH secondary timing chain tensioner and 2 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
23. Install the LH Variable Cam Timing (VCT) unit, exhaust camshaft sprocket and timing chain as an assembly.
24. Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger tight.
25. Remove the locking pin from the LH secondary timing chain tensioner.
26. Install the RH secondary timing chain tensioner and 2 bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
27. Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
28. Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger tight.
29. Remove the locking pin from the RH secondary timing chain tensioner.
30. Reset the timing chain tensioners.
1 Hold the lever toward the tensioner piston.
2 Using finger pressure, compress the tensioner.
3 Push the lever down and install a drill rod to lock the piston.
31. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Install the special tool on the LH head.
32. Position the LH timing chain and crankshaft gear.
^ Position the timing chain over the LH intake camshaft sprocket.
^ Position the crankshaft gear in the timing chain.
33. Install the LH timing chain guide and bolt.
^ Tighten to 11 Nm (8 ft. lbs.).
34. Install the LH timing chain tensioner arm and nut.
^ Tighten to 11 Nm (8 ft. lbs.).
35. Install the LH timing chain tensioner.
^ Install the timing chain tensioner and bolts, and remove the drill rod.
36. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
CAUTION: Using the special tool, apply 10 Nm(89 inch lbs.) counterclockwise to the LH exhaust camshaft sprocket.
Tighten the LH exhaust camshaft sprocket and Variable Camshaft Timing (VCT) unit bolts in 2 stages:
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
37. Remove the special tool.
38. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
Install the special tool on the right cylinder head.
39. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
40. Install the RH timing chain guide and bolt.
^ Tighten to 11 Nm (8 ft. lbs.).
41. Install the RH timing chain tensioner arm.
^ Tighten to 11 Nm (8 ft. lbs.).
42. Install the RH timing chain tensioner.
^ Install the timing chain tensioner and bolts, and remove the drill rod.
43. CAUTION: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
CAUTION: Using the special tool, apply 10 Nm (89 inch lbs.) counterclockwise to the RH exhaust camshaft sprocket.
Tighten the RH exhaust camshaft sprocket and VCT unit bolts in 2 stages:
^ Stage 1: Tighten to 35 Nm (26 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
44. Remove the special tool.
45. Remove the special tool.
46. NOTE: Lubricate the VCT bush carrier seals with clean engine oil.
Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting the bolts and nut.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
^ Tighten the nut to 10 Nm (89 inch lbs.).
47. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: If the sump is not secured within 4 minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply 3 continuous beads of silicone gasket and sealant to the areas shown.
48. Install the oil sump. Using a straightedge, align the sump to the lower cylinder block. Tighten the bolts in sequence in 2 stages.
^ Tighten the bolts to 15 Nm (11 ft. lbs.).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
49. Install the oil pump and the 4 bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
50. NOTE: Inspect the O-ring seal. Install a new O-ring seal if necessary. Lubricate the O-ring seal with clean engine oil.
Install the oil pump screen cover and tube.
^ Tighten to 12 Nm (9 ft. lbs.).
51. NOTE: Make sure all gasket sealing surfaces are clean and dry.
Install a new oil pan gasket, oil pan and 17 bolts.
^ Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten to 12 Nm (9 ft. lbs.).
52. Install new engine front cover gaskets.
53. NOTE: If the front cover is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in the 8 places shown.
54. Install the engine front cover.
^ Position the engine front cover on the cylinder block.
^ Loosely install the bolts.
^ Tighten the bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 inch lbs.).
- Stage 2: Tighten to 10 Nm (89 inch lbs.).
55. NOTE: Lubricate the front oil seal and the engine front cover mating surface with clean engine oil.
Using the special tool, install a new front crankshaft seal.
56. NOTE: If crankshaft pulley is not secured within 4 minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant to the keyway.
57. Using the special tool, install the crankshaft pulley.
58. Install a new bolt and using the special tool to hold the pulley, tighten in 4 stages.
^ Stage 1: Tighten to 80 Nm (59 ft. lbs.).
^ Stage 2: Loosen the bolt 2 complete turns.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
59. Install a new gasket, LH exhaust manifold, spacers and bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.) in the sequence shown.
60. Install a new gasket, RH exhaust manifold, spacers and bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.) in the sequence shown.